U.S. patent number 6,718,712 [Application Number 09/539,818] was granted by the patent office on 2004-04-13 for structural panel and method of fabrication.
Invention is credited to Mark David Heath.
United States Patent |
6,718,712 |
Heath |
April 13, 2004 |
Structural panel and method of fabrication
Abstract
Structural panels are provided which utilize commercially
available components and a cost effective method of fabrication.
The structural panels include commercially available trusses,
fillers positioned between and aligned with the trusses and
sandwiched to form a solid panel core, and commercially available
wire mesh substantially covering opposing side surfaces of the
panel core and attached to the trusses with wire to hold the panel
core together. The trusses include generally parallel rods and wire
bent around the rods in a zigzag configuration. The fillers may
include a foamed filler such as solid foamed plastic or solid
foamed glass. Alternatively, the filler may include a stabilized
organic material. A commercially available lathing member may also
be imbedded into the structural panel. The structural panels are
fabricated by aligning the fillers and trusses in an alternating
sequence. The alternating masonry reinforcement trusses and fillers
are then pressed to form a panel core. The wire mesh is overlied on
opposing side surfaces of the panel core and attached to the
trusses by attaching metal ties to connection points of the wire
mesh and trusses to hold the panel core together. A durable coating
can then be applied to the panel core and attached wire mesh.
Inventors: |
Heath; Mark David (Newhall,
CA) |
Family
ID: |
32044859 |
Appl.
No.: |
09/539,818 |
Filed: |
March 31, 2000 |
Current U.S.
Class: |
52/309.12;
52/368; 52/405.3; 52/454; 52/DIG.9 |
Current CPC
Class: |
E04C
2/044 (20130101); E04F 13/04 (20130101); E04F
13/047 (20130101); Y10S 52/09 (20130101) |
Current International
Class: |
E04C
2/04 (20060101); E04F 13/04 (20060101); E04F
13/02 (20060101); E04C 001/00 (); E04B 002/00 ();
E04F 013/04 () |
Field of
Search: |
;52/309.12,454,368,405.3,DIG.9,745.19,309.1,309.8,443,364,404.1,405.1 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Chapman; Jeanette E.
Attorney, Agent or Firm: Kelly, Bauersfeld, Lowry &
Kelley, LLP
Parent Case Text
RELATED APPLICATION
This application claims priority from provisional application Ser.
No. 60/127,224 filed Mar. 31, 1999.
Claims
What is claimed is:
1. A pre-fabricated structural panel, comprising: a plurality of
commercially available trusses having substantially parallel rods
of identical width interconnected by wire bent around the rods in a
zigzag configuration; a plurality of solid foamed glass fillers
positioned between and aligned with the trusses and sandwiched
therebetween under pressure to form a solid panel core;
commercially available wire mesh substantially covering opposing
side surfaces of the panel core and attached to the rods of the
trusses with commercially available metal ties to hold the panel
core together; and a commercially available lathing member imbedded
within the structural panel wherein said lathing member acts as a
secure anchor for attachment of at least one finished board.
2. The structural panel of claim 1, wherein the trusses comprise
masonry reinforcement trusses having wire bent around the rods at
approximately 30.degree. angles.
3. The structural panel of claim 1, including a durable coating
overlying the panel core and attached wire mesh.
4. A pre-fabricated structural panel, comprising: a plurality of
commercially available trusses having substantially parallel rods
of identical width interconnected by wire bent around the rods in a
zigzag configuration; a plurality of fillers comprised of
stabilized biomass positioned between and aligned with the trusses
and sandwiched therebetween to form a panel core; commercially
available wire mesh substantially covering opposing side surfaces
of the panel core and attached to the rods of the trusses with
commercially available metal ties to hold the panel core together;
and a commercially available lathing member imbedded within the
structural panel wherein said lathing member acts as a secure
anchor for attachment of at least one finished board.
5. The structural panel of claim 4, wherein the trusses comprise
masonry reinforcement trusses having wire bent around the rods at
approximately 30.degree. angles.
6. The structural panel of claim 4, including a durable coating
overlying the panel core and attached wire mesh.
Description
BACKGROUND OF THE INVENTION
The present invention relates generally to construction materials.
More particularly, the invention concerns structural panels and
methods for their manufacture which employ fillers comprised of
solid foamed materials or stabilized organic materials, together
with a reinforcing structure comprised of commercially available
components, which when assembled and faced with a durable covering
provides a building component.
Prefabricated structural building panels are utilized in the
construction of structures such as houses and commercial,
industrial and institutional buildings. They are also utilized in
the construction of non-building structures such as retaining
walls, fences, and cisterns. The pre-manufacturing of the panels
allows for lower costs and faster construction than available with
conventional, in-situ piecemeal construction.
Prefabricated structural panels are typically comprised of a filler
medium reinforced with metal lattice structures and surrounded by a
metal mesh or cage. A coating, such stucco, air blown cementitious
mixtures or the like, is added to complete the building process.
While these structural panels have been useful in the construction
industry, they have had the disadvantage of being costly and
sometimes unavailable in rural areas.
Lightweight plastic materials, including many different types of
foamed synthetic resins and expanded plastic foams such as
urethanes, polystyrenes, and the like, have a number of properties
that are highly desired in building materials for various types of
structures such as walls, roofs and the like, and these plastic
materials have been the customary filler material utilized in
structural panels. However, such materials are manufactured from
petrochemical substances and have potential environmental damage
issues associated with them. There is also the increasing price of
these fillers due to the finite quantity of petroleum resources and
their depletion. Additionally, there is the difficulty in obtaining
plastic foams in developing countries and remote locations as well
as the high cost of shipping to these locations due to plastic foam
volume to weight ratio.
Companies which provide structural panels produce their own
specialized metal lattice structures and metal meshes having
various wire gauges and wire bends which deviate from industry
standards. For example, industry standard masonry reinforcement
trusses use a zigzag configuration having approximately thirty
degree (30.degree.) bends. At least one company produces lattice
structures having forty-five (45.degree.) bends for use in their
structural panels, a configuration which is more structurally sound
but which also increases the cost of the structural panel due to
production costs. Typically, such structural panels are limited to
only one thickness option. The wire gauges of the wire mesh are
often altered at key structural points to reinforce the structural
panel. While structurally superior, these designs result in
increased expense passed to the end consumer. The design of the
structural panel may also be complicated which further increases
production costs. For example, the structural panel of U.S. Pat.
No. 5,487,248 (incorporated by reference herein) utilizes preformed
plastic foamed filler elements which create chambers when brought
together for the later insertion of wires, pipes, etc., used within
the building. In rural areas and foreign countries many of these
specialized materials are not available and must be shipped,
further increasing expense or prohibiting the area from using
prefabricated structural panels altogether.
Accordingly, there is a need for a composite structural panel that
utilizes commercially available components and tooling to reduce
the costs associated therewith. What is also needed is a structural
panel which incorporates filler mediums that are readily available
or producible in rural areas. The present invention fulfills these
needs and provides other related advantages.
SUMMARY OF THE INVENTION
The present invention relates to pre-fabricated structural panels
which utilize commercially available materials, and a
cost-efficient and simple method of construction. Accordingly, the
main objective of this invention is a novel and improved structural
panel which can be constructed in a wide variety of thicknesses,
widths and lengths without dependence on limited source and costly
materials.
The structural panels are generally comprised of a plurality of
commercially available trusses, such as masonry reinforcement
trusses, etc., and a plurality of fillers positioned between and
aligned with the trusses. The fillers are sandwiched between the
trusses to form a solid panel core. Commercially available wire
mesh, substantially covering opposing side surfaces of the panel
core, is attached to the trusses with metal ties to hold the panel
core together.
In the preferred form of the invention, the trusses comprise
substantially parallel rods having wire bent around the rods in a
zigzag configuration at approximately thirty degree (30.degree.)
angles. The fillers may be comprised of a foamed filler such as
solid foamed plastic or solid foamed glass. Alternatively, the
filler is comprised of a stabilized organic material.
A commercially available lathing member may be imbedded into the
structural panel for later attachment of drywall and the like.
To fabricate the structural panels, the fillers and trusses are
first aligned in a alternating sequence. The alternating trusses
and fillers are then pressed to form a panel core. The wire mesh is
placed over opposing side surfaces of the panel core and attached
to the trusses by attaching metal ties, such as bailing wire, to
connection points of the wire mesh and trusses to hold the panel
core together. A durable coating is later applied to the panel core
and attached wire mesh.
Other features and advantages of the present invention will become
apparent from the following more detailed description, taken in
conjunction with the accompanying drawings which illustrate, by way
of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate the invention. In such
drawings:
FIG. 1 is an elevational view of a commercially available truss
used in accordance with the present invention;
FIG. 2 is an elevational view of a panel core having alternating
trusses and fillers;
FIG. 3 is a schematic view illustrating the positioning of a wire
mesh adjacent to opposing side surfaces of the panel core of FIG. 2
after compressing the panel core; and
FIG. 4 is a partly fragmented perspective view of a fabricated
structural panel embodying the present invention and having a
durable coating applied thereto.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the present invention, an exemplary commercially
available truss 1 is illustrated in FIG. 1. The truss 1 generally
comprises a wire 11 having a series of bends 12 around a pair of
mutually spaced apart side rods 13. The rods 13 are laid in
parallel fashion along the bends 12 of wire 11 and welded or
otherwise attached to the wire 11 to provide a generally planar
configuration. The trusses 1 are constructed and sold in varying
widths which can be utilized for the creation of different
thicknesses of structural panels. Such trusses 1 include commonly
available masonry reinforcement trusses and space frame trusses,
although other commercially available trusses may be used.
As is common in the industry, center wire 11 is bent in a zigzag
configuration to provide strength to the truss. The angle of the
bends 12 may be varied depending on structural loading imposed on
the panel, for example masonry reinforcement trusses traditionally
have approximately either 30.degree. or 60.degree. wire bends as
shown in the drawings to form triangles within the trusses 1. Of
course, other commercially available trusses may have different
angles within the bent wire. The gauge of the side rods 13 and the
bent wire 11 may be varied to resist varying loads. For example, a
10 gauge wire may be used for heavier load applications and a 12
gauge wire for lighter load applications. The side rods 13 and the
bent wire 11 may be smooth wire or deformed. The use of deformed
wire creates greater mechanical adhesion between said wires and a
cementitious coating 5 as will be further described.
As shown in FIGS. 2 through 4, a panel core 8 of the structural
panel 10 of this invention includes a plurality of elongated filler
members 2 in face-to-face contact at surfaces 21 and 22 with the
trusses 1 interdigitated with the filler members 2. The plurality
of elongated filler members 2 lie in a mutually contiguous
arrangement. Between opposed surfaces 21 and 22 of the filler
members 2 are alternatingly placed trusses 1 of the type shown in
FIG. 1 and aligned with the filler members 2. Each elongated filler
member 2 has opposite side surfaces 23 extending generally normal
to said opposed surfaces 21 and 22 as shown in FIG. 2. A
rectilinear cross-section is the norm but not necessary.
Trapezoidal shapes would allow for the construction of curvilinear
panels.
The filler members 2 can be of a solid foamed type, such as solid
plastic foamed material or glass foamed material. The elongated
filler members 2 may also be made from a variety of organic
materials comprising agricultural waste or biomass, such as straw
or wood chips hammer milled or otherwise broken and added to a
stabilizer such as cement. The primary requirement is that the
finished organic filler element have sufficient physical strength
to be useful over the period of time of manufacture and erection of
the panels and resist the stresses of the application of the
cementitious covering 5. The stabilizer should prevent the
environment, insects, rodents and the like, from eating away or
degrading the organic material. The foamed material or stabilized
organic material is made into the required shape and dimensions to
form a panel core sub-assembly. The organic material filler member
2 can be blown into plastic bags or combined with a polymer and
poured, extruded or otherwise formed into free standing members as
is known in the art.
The use of an organic filler material in the form of biomass or
agricultural waste instead of the plastic filler material of prior
art allows for the panels to be made more readily in areas where
plastic filler materials are not readily available or cost
prohibitive. Wood chip concrete is a common material which could be
employed as the filler material, however other organic materials
which could be formed in the requisite shape would serve to
accomplish the desired panel configuration. Examples include corn
stocks, bamboo, kenaf, rice hulls, rice straw, orchard thinnings,
grain straw, shredded paper, scrub brush, or any organic fibrous
material (i.e. biomass or agricultural waste) which could be formed
into the needed shape. The organic filler material can be formed to
size or can be formed in panels or blocks of larger sizes for
efficiency of manufacture and then cut to size. In addition to
utilizing cement as a binder for the organic material, the use of
plastic additives such as recycled PET bottles, the use of recycled
tires, the use of asphalts, adhesives or binders generated by the
plants under imposed conditions such as steam and pressure, can all
be utilized to form the organic material into shapes which can be
employed in the fabrication of the structural panels 10.
As shown in FIG. 3, lateral compressive pressure is applied to the
layered filler members 2 and trusses 1 by a suitable press 100.
Thus, the trusses 1 are sandwiched between the opposed surfaces 21
and 22 of each filler member 2 to form a solid core 8. Preferably,
the resultant structure is a plurality of filler members 2 stacked
together wherein the opposed surfaces 21 and 22 are held tightly
together with the layers of trusses 1 imbedded in surfaces 21 and
22. However, only sufficient pressure to allow for the application
of the wire mesh 3 is required. Where less pressure is applied such
that the completed panel is not rigid of itself, a straightening
rod (not shown) may be temporarily applied in the field, so that
sufficient rigidity is available for the application of the coating
5. Having a less rigid core panel 8 can also present some
application advantages where curvilinear structures are desired.
While the norm is for the press 100 to be a mechanical apparatus,
it may be sufficient to have the press be nothing more than hand
pressure. The press does not need to be bi-directional. There may
be sufficient compression achieved with pressure generated from one
side 101 of the stacked members against a fixed surface on the
opposite side 102 of the stack.
A wire mesh 3, formed of lateral wires 31 and longitudinal wires
32, is laid against the side surfaces of the pressed core of
trusses 1 and filler members 2 and attached to the rods 13 with
commercially available metal ties 4, such as upholstery C-clamps,
concrete reinforcement wires, or bailing wire cut to an appropriate
length. The ties 4 are attached by hand, pliers or other
appropriate tools. The wire mesh 3 is preferably applied to both
sides of the trusses 1 so that the resulting structural panel
contains filler members 2 interdigitated with trusses 1, with
overlays of wire mesh 3 on both sides. The wire mesh 3 can be
comprised of a wire netting, such as chicken wire as is commonly
used in plastering applications, as well as the pre-manufactured
wire netting assemblies such as k-lath. Other commercially
available wire meshes 3 may also be used as suits the demands of
the structure to be built. These commercially available wire meshes
3 are typically of a single gauge of wire in both the latitudinal
31 and longitudinal 32 directions. In some cases, however, the
latitudinal wire 31 will be of one gauge while the longitudinal
wire 32 will be of a different gauge.
Commercially available lathing members 15 such as metal sheets or
furring channels may be added to the structural panel 10, typically
within the wire mesh 3, to act as a secure anchor for later
attachment of a finished board such as drywall, gypsum board or the
like.
In use, the structural panel 10 of this invention is arranged
horizontally or vertically, depending on the loads being imposed.
The structural panel 10 can be employed in the construction of
structures by itself or it may be integrated with other building
materials. Some examples would be: (1) employ the structural panel
10 in the construction of roofs on masonry or adobe walls; (2) the
construction of in-fill walls in steel or concrete post-and-beam
framed structures; (3) the construction of floors in the
aforementioned construction types; (4) retaining walls; (5) fences;
and (6) hardscape features such as tables and benches. By selecting
trusses 1 of differing wire 11 or rod 13 gauge, or by changing the
gauge of the wires 31 and/or 32 in the wire mesh 3, the strength of
the structural panel 10 can be varied. Additionally, multiples of
trusses 1 or multiple layers of wire mesh 3 may be used to vary the
strength of the structural panel 10.
After the completed structural panel 10 is erected to form the
desired structure or building, it is then covered with a
cementitious coating 5 resulting in a hard, durable and
substantially planar finished surface. The norm is for this coating
5 to be a sand-cement plaster mix but it could be any of the
air-placed cementitious materials (shotcrete, gunnite, etc.) or
could be an adobe material. Additionally, modern coating materials
such as hybrid concretes, glass fiber reinforced concrete,
cement-plastic, or foamed concrete materials could all be employed
to meet specialized or customized needs. It is also possible to
pre-cast the coatings 5 on the structural panels 10 and then erect
the pre-coated structural panels. The structural panels 10 can also
be used to create an insulating and reinforcing core in
form-and-pour concrete or form-and-pour earthen systems.
The primary advantage of the present invention is that the
components of the structural panel are widely available, even in
rural areas or foreign countries, which dramatically reduces the
costs associated with the prefabricated structural panels.
Particularly in third world countries, organic materials as
described above which would otherwise be disposed of can be used in
the construction of buildings and other structures.
Although several embodiments have been described in detail for
purposes of illustration, various modifications may be made without
departing from the scope and spirit of the invention. Accordingly,
the invention is not to be limited, except as by the appended
claims.
* * * * *